Spring clip for photovoltaic module mounting

ABSTRACT

A module mounting system may include a photovoltaic (PV) module frame including a mounting rail. The module mounting system may include a spring clip with a PV module frame interfacing element and a clip interfacing element. The spring clip may apply spring force via deformation to lock the PV module frame and a clip together. A second embodiment of the spring clip may include an upper component having one or more arms and a lower component having a central loop configured to rotate relative to each other and interface with the PV module frame or the mounting rail. A second embodiment of the module mounting system may include screwless clips including outer walls and inner walls coupled together as a continuous sheet of material. The screwless clips may couple to a respective mounting flange and a respective frame flange to lock the mounting purlin and the PV module frame together.

CROSS-REFERENCE TO RELATED APPLICATION

This application is a divisional of U.S. patent application Ser. No.17/474,607, filed on Sep. 14, 2021, which claims the benefit of andpriority to U.S. Patent Application Ser. No. 63/078,177, filed on Sep.14, 2020, and U.S. Patent Application Ser. No. 63/195,629, filed Jun. 1,2021; the disclosures of which are incorporated herein by reference inits entirety.

THE FIELD OF THE DISCLOSURE

The present disclosure generally relates to spring clips forphotovoltaic (“PV”) module mounting.

BACKGROUND

Most PV modules are quite heavy because they use glass to encase the PVcells. A solar tracking system, therefore, must be able to withstand theweight of an array of one or more PV modules and the forces of naturethat may act upon it. In addition to supporting heavy solar arrays andthe associated natural forces, solar tracking equipment must also beable to move the solar array so it tracks the sun. The PV modules withtheir associated frames must be mounted to the support structure of thesolar array and the solar tracking equipment. However, there is a needfor improved mounting approaches.

The subject matter claimed in the present disclosure is not limited toembodiments that solve any disadvantages or that operate only inenvironments such as those described above. Rather, this background isonly provided to illustrate one example technology area where someembodiments described in the present disclosure may be practiced.

SUMMARY

One or more embodiments of the present disclosure may include a modulemounting system that includes a photovoltaic (PV) module frame enclosingone or more PV cells. The module mounting system may also include amounting rail shaped to interface with the PV module frame and one ormore support structures to which the mounting rail is coupled to keepthe mounting rail off the ground.

One or more embodiments of the present disclosure may include a modulemounting system that includes a mounting purlin including one or moremounting flanges extending horizontally from the mounting purlin and aPV module frame including one or more frame flanges extendinghorizontally from the PV module frames in which each of the frameflanges may interface against a respective mounting flange of themounting purlin. The module mounting system may also include one or morescrewless clips interfacing with the mounting flanges and the frameflanges in which each of the screwless clips includes one or more outerwalls and one or more inner walls formed of a continuous sheet ofmaterial in a generally W-shaped profile.

The object and advantages of the embodiments will be realized andachieved at least by the elements, features, and combinationsparticularly pointed out in the claims. It is to be understood that boththe foregoing general description and the following detailed descriptionare explanatory and are not restrictive of the invention, as claimed.

BRIEF DESCRIPTION OF THE DRAWINGS

To further clarify the above and other advantages and features of thepresent disclosure, a more particular description of the disclosure willbe rendered by reference to specific embodiments thereof which areillustrated in the appended drawings. It is appreciated that thesedrawings depict only typical embodiments of the disclosure and aretherefore not to be considered limiting of its scope. The disclosurewill be described and explained with additional specificity and detailthrough the use of the accompanying drawings in which:

FIGS. 1A-1D illustrate an example embodiment of a module mounting systemwith a spring clip in accordance with the present disclosure;

FIGS. 2A-2D illustrate another example embodiment of a module mountingsystem with a spring clip in accordance with the present disclosure;

FIGS. 3A-3E illustrate an additional another example embodiment of amodule mounting system with a spring clip in accordance with the presentdisclosure;

FIG. 3F illustrate another example embodiment of a module mountingsystem with a spring clip in accordance with the present disclosure;

FIG. 4A illustrates a first example embodiment of a first screwless clipfor fastening PV module frames according to the present disclosure;

FIG. 4B illustrates an example embodiment of a second screwless clip forfastening PV module frames according to the present disclosure;

FIG. 5A illustrates a first example embodiment of a first mountingpurlin according to the present disclosure;

FIG. 5B illustrates a second example embodiment of a second mountingpurlin according to the present disclosure;

FIG. 6A illustrates a view of an example embodiment of a first mountingassembly including the first screwless clip and the first mountingpurlin coupled to a PV module frame according to the present disclosure;

FIG. 6B illustrates a second view of the example embodiment of the firstmounting assembly illustrated in FIG. 6A, according to the presentdisclosure;

FIG. 6C illustrates a side view of the example embodiment of the firstmounting assembly illustrated in FIG. 6A, according to the presentdisclosure;

FIG. 6D illustrates a front view of the example embodiment of the firstmounting assembly illustrated in FIG. 6A, according to the presentdisclosure;

FIG. 6E illustrates a view of an example embodiment of a second mountingassembly including the second screwless clip illustrated in FIG. 4B andthe second mounting purlin illustrated in FIG. 5B coupled to a PV moduleframe according to the present disclosure;

FIG. 7A illustrates an example embodiment of a third screwless clipaccording to the present disclosure;

FIG. 7B illustrates an example embodiment of a fourth screwless clipaccording to the present disclosure; and

FIG. 7C illustrates an example embodiment of a fifth screwless clipaccording to the present disclosure.

DETAILED DESCRIPTION

The present disclosure relates to improvements in mounting approachesfor mounting PV modules and their associated frames to the supportstructure of an array of PV modules. For example, a row of PV modulesmay be mounted to a torque tube that facilitates tracking of the sunwith the PV modules. In the present disclosure, a module mounting systemmay include a PV module frame for holding the PV modules themselves, anda mounting rail that is fixedly coupled to a torque tube or othersupport structure of the array of PV modules. According to the presentdisclosure, a spring clip may operate to lock the PV module framerelative to the mounting rail. The spring clip may provide a device thatgenerates spring force due to deformation of the spring clip and appliesthe spring force to the PV module frame and the mounting rail, lockingthem into place relative to each other. Various implementations of theform factor of the spring clip are contemplated within the presentdisclosure.

By using a spring clip in accordance with at least some of theembodiments of the present disclosure, a tool-less installation approachmay be undertaken. For example, instead of maintaining and keeping alarge number of pneumatic drivers, battery-operated drills, andcalibrated torque wrenches that are able to drive bolts or otherconnecting devices to specified torques and have quality controlfeatures in place to verify such machinery, the tool-less installationmay avoid all such costs and burden. With threaded fasteners, theclamping force is achieved through the application of torque on thefastener, which in an uncontrolled outdoor environment is inherentlyvariable based on the condition of the threads, tools, etc. Instead, anyconstraints or concerns regarding proper force-loading, etc. may beundertaken during quality control of a manufacturing process and/or thedesign process for the spring clips themselves, where it is easier tocontrol. The spring clips may be designed to lock the mounting rail andthe PV module frame together even when exposed to expected forces, suchas wind, snow, rain, solar tracking, etc. Additionally, the spring clipsmay be designed to be installed by hand, or with the assistance of asimple off-the-shelf tool like a crowbar or prybar. While the use ofcustomized tools is within the scope of the present disclosure, the useof such tools may or may not be required, depending on the design of thespring clip.

The present disclosure also relates to clips that may be used to couplea PV frame to a mounting rail or other structure, such as a mountingpurlin. The clip may include features to bite into either or both of thePV frame and mounting structure to facilitate locking the two componentstogether and/or facilitate electrically coupling the two together toprovide grounding of the PV frame to the mounting structure. In someembodiments, one or both of the structures being coupled together mayinclude a gap or hole into which a tooth or locking lip may extend tolock the clip into place and/or to lock the PV frame and the mountingstructure together.

In the following paragraphs, embodiments will be described in detail byway of example with reference to the accompanying drawings, which may ormay not be drawn to scale, and the illustrated components are notnecessarily drawn proportionately to one another. Throughout thisdescription, the embodiments and examples shown should be considered asexamples, rather than as limitations of the present disclosure. As usedherein, the “present disclosure” refers to any one of the embodimentsdescribed herein, and any equivalents. Furthermore, reference to variousaspects of the disclosure throughout this document does not mean thatall claimed embodiments or methods must include the referenced aspects.

FIGS. 1A-1D illustrate an example embodiment of a module mounting system100 with a spring clip 110 in accordance with the present disclosure.The module mounting system 100 may include a PV module frame 150 forholding the PV modules themselves, and a mounting rail 160 that isfixedly coupled to a torque tube or other support structure of the arrayof PV modules. The spring clip 110 may operate to lock the PV moduleframe 150 relative to the mounting rail 160.

The spring clip 110 may include one or more PV module interfacingportions, such as wings 112, for interfacing with flanges 152 of the PVmodule frame 150. The wings 112 may be spaced apart such that (as shownin FIG. 1A) one wing 112 b of the spring clip 110 may be slid over oneflange 152 b and still have room for the other wing 112 a to slide pastthe other flange 152 a. Once past the other flange 152 a, the springclip 110 may be centered between the two flanges 152 such that bothwings 112 are interfacing with the flanges 152.

As illustrated in FIG. 1C, after being mounted over the flanges 152 ofthe PV module frame 150, the spring clip 110 may be slid towards themounting rail 160. The mounting rail 160 may include a lock ramp 162formed into a surface of the mounting rail opposite the surface thatinterfaces with the PV module frame 150. The spring clip 110 may includea mounting rail interfacing portion, such as a central loop 114 that issized to correspond to the locking ramp 162. As the spring clip 110 isslid along the length of the PV module frame 150 toward a final positionof the spring clip 110, the central loop 114 of the spring clip 110 mayinterface with, and then be forced up and over the locking ramp 162,such as shown in FIG. 1D.

In some embodiments, the lock ramp 162 may have a feature, shape,protrusion, etc. to prevent the spring clip 110 from shifting back upover the lock ramp 162. For example, the lock ramp 162 may have aprofile like that of a shark dorsal fin.

In some embodiments, the spring clip 110 may be designed and shaped suchthat a certain amount of force is applied to each of the flanges 152 ofthe PV module frame 150 and the mounting rail 160, effectively pinchingthe PV module frame 150 and the mounting rail 160 together. In these andother embodiments, the applicable force may be determined as of when thespring clip 110 is in the position illustrated in FIG. 1D. The springclip 110 may be designed to provide sufficient spring force to keep thePV module frame 150 and the mounting rail 160 locked in positionrelative to each other when experiencing known forces applied to the PVmodule frame 150 and mounting rail 160. Such forces may include theweight of the PV modules themselves, the forces due to rotating a torquetube when tracking the sun, forces due to wind, rain, snow, etc., or anyother forces to which the PV module frame 150 and mounting rail 160 areknown to be exposed.

In some embodiments, the spring clip 110 may apply forces to the PVmodule frame 150 and the mounting rail 160 even before being forced upand over the lock ramp 162. For example, the central loop 114 may bepositioned such that in a passive form of the spring clip 110, thecentral loop 114 is closer to the PV module frame 150 than the surfaceof the mounting rail 160 such that the spring clip 110 is deformed afirst amount to get the central loop onto the surface of the mountingrail 160. As the spring clip 110 is slid along, up, and over the lockramp 162, the spring clip 110 may be deformed a further amount and mayreturn to approximately the first amount of deformation after droppingin past the lock ramp 162.

While the example of a single spring clip 110 is illustrated, it will beappreciated that multiple spring clips 110 may be used to couple the PVmodule frame 150 with the mounting rail 160.

FIGS. 2A-2D illustrate another example embodiment of a module mountingsystem 200 with a spring clip 210 in accordance with one or moreembodiments of the present disclosure. The module mounting system 200may include similarly numbered components and elements as illustrated inFIGS. 1A-1D, such as a PV module frame 250 that may be similar orcomparable to the PV module frame 150, and a mounting rail 260 that maybe similar or comparable to the mounting rail 160. FIG. 2A illustrates aperspective view of the spring clip 210 locked into place as alsoillustrated in FIG. 2D.

As illustrated in FIGS. 2A-2D, the mounting rail 260 may include a slot262 within which the spring clip 210 may reside. For example, during amanufacturing process, the spring clip 210 may be formed at leastpartially in the slot 262 such that the spring clip 210 is captive inthe slot 262. In this way, when shipping and/or arranging forinstallation, an installer does not need to be aware of or concernthemselves with carrying the spring clips 210 separately as they will belocated within the slot 262.

The spring clip 210 may be shaped with arms 212 configured to project upinto holes in the flanges of the PV module frame 250 placed tocorrespond with the slot 262 and the spring clip 210. For example, asillustrated in FIG. 2B, the PV module frame 250 may be positioned atopthe mounting rail 260 such that the arms 212 of the spring clip 210 areable to project up into the hole.

As illustrated in the transitions from FIGS. 2B to FIGS. 2C and 2D, thespring clip 210 may be pushed back along the slot 262 and transitionfrom an initial position shown in FIG. 2B to a final position shown inFIG. 2D by rotating about the base of the arms 212. In some embodiments,the flexion of the angle in the spring clip 210 near the arms 212provides the spring force to lock the PV module frame 250 and themounting rail 260 together.

As illustrated in FIG. 2D, in some embodiments, the slot 262 may includea lock ramp 263 such that as the spring clip 210 is forced up and overthe lock ramp 263 towards a final position of the spring clip 210, thespring clip 210 may drop into the end of the slot 262 on the other sideof the lock ramp 263 to lock the spring clip 210 into place (e.g., afterreaching the final position of the spring clip 210). In these and otherembodiments, the spring clip 210 and/or the slot 262 may be designedsuch that when in the position illustrated in FIG. 2D, the spring forceof the spring clip 210 is sufficient to lock the mounting rail 260 andthe PV module frame 250 relative to each other even when experiencingexpected forces (e.g., forces due to wind, rain, solar tracking, etc.).

In some embodiments, the slot 262 may extend to the edge of the mountingrail 260 such that the edge is open. In these and other embodiments, thespring clips 210 may be manufactured and/or shipped separately from themounting rail 260. The spring clip 210 may be loaded within the slot 262and then the arms 212 may be inserted into the holes in the PV moduleframe 250 and pushed back over the lock ramp 263 to lock the spring clip210 into place. In these and other embodiments, a locking device (notshown) may be placed over the edge of the mounting rail 260 and/or inthe slot 262 to prevent the spring clip 210 from rotating back up andover the lock ramp 263, or from coming out of the slot 262.

FIGS. 3A-3F illustrate an additional example embodiment of a modulemounting system 300 with a spring clip 310 in accordance with thepresent disclosure. The module mounting system 300 may include similarlynumbered components and elements as illustrated in FIGS. 1A-1D and/orFIGS. 2A-2D, such as a PV module frame 350 that may be similar orcomparable to the PV module frames 150 and/or 250, and a mounting rail360 that may be similar or comparable to the mounting rail 160 and/or260. The spring clip 310 may operate in a manner similar to a spring topbottle in locking the PV module frame 350 and the mounting rail 360together.

The spring clip 310 may include an upper component with arms 312, and alower component with a central loop 314. The upper portion and lowerportion may include a hinge point 316 (such as the hinge points 316 aand 316 b on each side of the spring clip as shown in FIG. 3D) aboutwhich upper component and lower component rotate relative to each other.For example, the upper component may include a post that extends througha hole in the lower component to make the hinge point 316, although anyconfiguration that permits the two components to rotate relative to eachother is within the scope of the present disclosure (e.g., the lowercomponent may include the post and the upper component may include thehole, etc.).

In some embodiments, ends of the lower component may extend through ahole in the mounting rail 360 to form a pivot point 318 (such as thepivot points 318 a and 318 b on either side of the spring clip 310)about which the entire spring clip 310 may rotate relative to themounting rail 360. By using the combination of the hinge point 316 andthe pivot point 318, the spring clip may be able to rotate back and lockinto place, as observed in the transitions from FIGS. 3A, to 3B, to 3C.For example, the central loop 314 may be rotated down and around the endof the mounting rail 360 until the central loop 314 is against thebottom surface of the mounting rail 360 (e.g., the surface on theopposite side from the PV module frame 350). As another example, arms312 b of the upper component as illustrated in FIG. 3E may extend upwardas the lower component is rotated such that the arms 312 b extendthrough corresponding holes in the mounting rail 360 and/or the PVmodule frame 350.

When moving from an initial open position (e.g., as shown in FIG. 3A) toa final locked position (e.g., as shown in FIG. 3C), the hinge point 316may move from one side of the pivot point 318 to another. By doing so,the arm 312 may prevent and/or resist the upper component from shifting,and as the hinge point 316 and pivot point 318 are aligned vertically,the greatest compressive force is applied to the PV module frame 350 andthe mounting rail 360. As the hinge point 316 moves past the pivot point318, the physical forces tend to force the central loop 314 against themounting rail 360 as the physical forces attempt to rotate the hingepoint 316 further past the pivot point 318 to reduce the compressiveforce.

In some embodiments, the mounting rails 360 may be manufactured and/orshipped for installation with the spring clip 310 already with poststhrough the holes at the pivot point 318. During installation, the PVmodule frame 350 may be moved laterally relative to the mounting rail360 until a hole corresponding to the arm 312 may be in position suchthat the arm 312 may be guided up through the hole. In some embodiments,such guidance may utilize movement of the PV module frame 350 relativeto the mounting rail 360. The hole for the arm 312 in the PV moduleframe 350 may be similar or comparable to the hole described withreference to FIGS. 2A-2D.

In these and other embodiments, the spring clip 310 may be designed suchthat when in the locked position (e.g., illustrated in FIG. 3C), thespring clip 310 may apply sufficient force to lock the PV module frame350 relative to the mounting rail 360 when exposed to the expectedforces.

In some embodiments, the mounting rail 360 may include a lock ramp (notillustrated) along a bottom surface of the mounting rail 360. As thecentral loop 314 progresses up and over the lock ramp and past the lockramp, the lock ramp may include a feature to prevent the central loop314 from rotating back over the lock ramp. For example, the lock rampmay include a similar shape or profile as that illustrated for the lockramps 162 and 263 in FIG. 1C and/or FIG. 2D, respectively.

As illustrated in FIG. 3F, in some embodiments, a spring clip 311 (whichmay be similar or comparable to the spring clip 310) may include arms313 (such as the arms 313 a/313 b) rather than the arms 312. Forexample, the arms 313 a and 313 b may be positioned to rotate up andaround the outside of the PV module frame 350 such that the arms 313a/313 b may press against the top surface of the PV module frame 350rather than projecting up and through the PV module frame 350 for thearms 312. After being rotated up and into position atop the PV moduleframe 350, the central loop 314 may be rotated into the locked positionin a similar or comparable manner to that described with reference toFIGS. 3A-3E.

Modifications, additions, or omissions may be made to any of FIGS. 1A-3Fof the present disclosure. For example, changes as described herein maybe made in accordance with the knowledge of a person of ordinary skillin the art. For example, the mounting rail and/or the PV frames may takeany form or shape, and the spring clip shape may be adjusted toaccommodate any such changes.

In some embodiments, the spring clips of the various embodiments of thepresent disclosure may be formed via a single span of metal rod that maybe formed, shaped, bent, etc. to have the form illustrated in FIGS.1A-3F. Additionally, or alternatively, the spring clips may be formedvia multiple spans of metal joined or coupled together into the formsillustrated in FIGS. 1A-3F. In some embodiments, various portions of thespring clip may be pressed, stamped, or otherwise formed to have a flatsurface rather than a rounded surface, such as the surfaces of the wingsand/or the central loop that interface with the flanges and the mountingrail, respectively.

FIG. 4A illustrates a first example embodiment of a first screwless clip400 a for fastening PV module frames according to the presentdisclosure. The screwless clip 400 a may include one or more outer walls410 a and one or more inner walls 420. In some embodiments, thescrewless clip 400 a may include two outer walls 410 a and two innerwalls 420 such that the screwless clip includes a W-shaped profile. Insome embodiments, the outer walls 410 a and the inner walls 420 may beformed from one or more continuous sheets of material, such as metal.For example, the screwless clip 400 a may be shaped by a roll-formingprocess, molding, casting, welding two or more sheets together, etc. Insome embodiments, the screwless clip 400 a may be shaped to includeinherent structural strength in a vertical direction, which may preventthe PV module frame and/or the mounting purlin from separating underloads. As such, the inner walls 420 may include a greater height thanthe outer walls 410 a. In these and other embodiments, the screwlessclip 400 a may be formed via a roll-forming process from steel and/orusing materials such as extruded aluminum, cast iron, stainless steel,high-density polyethylene, polyvinyl chloride, etc. In some embodiments,the screwless clip 400 a may be formed of a material that iselectrically conductive.

The outer walls 410 a may include locking tabs 440 and/or a lockingrecession 442 a. In some embodiments, the locking tabs 440 and/or thelocking recession 442 a may interface with a surface of a flangecorresponding to the mounting purlin and/or the PV module frame tofacilitate fastening the PV module frame to the mounting purlin. In someembodiments, the outer walls 410 a may include the locking tabs 440 onone or more edges of the outer walls 410 a such that the locking tabs440 of the outer walls 410 a are oriented in an upward-facing direction.In some embodiments, the outer walls 410 a may include the lockingrecession 442 a on the edges of the outer walls 410 a adjacent to thelocking tabs 440. In these and other embodiments, the locking recession442 a may be positioned behind the locking tabs 440 along the same edgeas the locking tabs 440 such that the locking recession 442 a ispositioned closer to the center of the edge of the outer walls 410 athan the locking tabs 440. Additionally or alternatively, the innerwalls 420 may include grounding teeth 430 configured to interface with asurface of the mounting purlin and/or the PV module frame.

In some embodiments, a slot opening 425 may be included in one or moreof the inner walls 420, and the grounding teeth 430 may be formed alonga top edge of the slot opening 425. The width of the slot opening 425may be smaller than the thickness of a mounting flange of a mountingpurlin and/or a frame flange of a PV module frame to which the screwlessclip 400 a is coupled such that the screwless clip 400 a exerts a presetamount of clamping force on the flanges of the mounting purlin and/orthe PV module frame. In some embodiments, the locking tabs 440 mayinterface with adjoining holes in the PV module frame and/or themounting purlin to reduce and/or prevent relative sliding motionsbetween the PV module frame and the mounting purlin.

In some embodiments, the grounding teeth 430 and/or teeth on the lockingtabs 440 may work in cooperation to provide a resistive force relativeto the screwless clip 400 a being removed after being slid into place tocouple a surface of the mounting purlin and/or the PV module frame. Forexample, the grounding teeth 430 and/or the teeth on the locking tabs440 may be oriented towards the back of the slot opening 425 such thatas a force is applied to draw the screwless clip 400 a away from thesurface of the mounting purlin and/or the PV module frame, the groundingteeth 430 and/or the teeth on the locking tabs 440 may bite in deeper tothe material, acting as barbs.

FIG. 4B illustrates a second example embodiment of a second screwlessclip 400 b for fastening PV module frames according to the presentdisclosure. In some embodiments, the screwless clip 400 b may includeinner walls that are the same as or similar to the inner walls 420 ofthe screwless clip 400 a in that a slot may be included in the surfaceof each inner wall and grounding teeth may be included along a top edgeof the slot. Additionally or alternatively, the screwless clip 400 b mayinclude a semicircular locking recession 442 b along one or more outerwalls 410 b of the screwless clip 400 b without locking tabs includedalong the top edge of the outer walls 410 b. Although illustrated assemicircular in shape, the locking recession 442 b may take any shape(such as rectangular, rounded rectangular, etc.).

FIG. 5A illustrates a perspective view of a first example embodiment ofa first mounting purlin 500 a according to the present disclosure. Thefirst mounting purlin 500 a illustrated in FIG. 5A may include ashort-section view of a mounting purlin, and a length of the firstmounting purlin 500 a may vary depending on a length of the PV modulescoupled to the first mounting purlin 500 a. For example, the firstmounting purlin 500 a may include a longer length to accommodate alonger PV module length (or a shorter length to accommodate a shorter PVmodule length). In some embodiments, the mounting purlin 500 a mayinclude a seating section 510, one or more mounting flanges 520 a,and/or one or more mounting slots 530. In these and other embodiments,the mounting purlin 500 a may include any shape, such as a circularshape, triangular shape, an aperture opening, etc.

The mounting flanges 520 a and/or the mounting slots 530 may extendlaterally from the top of the seating section 510 (e.g., from a “brim”of the top-hat shaped mounting purlin 500 a). In some embodiments, themounting flanges 520 a may be flat or substantially flat such that aflange of the PV module frame may be positioned flush against themounting flange 520 a. Additionally or alternatively, a screwless clip,such as the screwless clips 400 a and/or 400 b (collectively “screwlessclip(s) 400”), may interface with the mounting purlin 500 a via themounting flanges 520 b and/or the mounting slots 530. In someembodiments, the mounting slots 530 may provide an opening through whichthe grounding teeth of the screwless clip 400 and/or the locking tabs440 may extend to secure the screwless clip 400 to the mounting purlin500 a and/or reduce and/or prevent sliding movement of the screwlessclip 400 and/or the PV module frame.

FIG. 5B illustrates an example embodiment of a second mounting purlin500 b according to the present disclosure. In some embodiments, thesecond mounting purlin 500 b may include one or more mounting flanges520 b, and each of the mounting flanges 520 b may include an edge lip535 along part of or an entire edge of one or both of the mountingflanges 520 b. In these and other embodiments, the edge lip 535 may beconfigured to interface with the locking recession 442 b of thescrewless clip 400 b described in relation to FIG. 4B. For example, oneof the mounting flanges 520 b may extend into a slot of the screwlessclip 400 b, and the edge lip 535 may interface with the lockingrecession 442 b in the outer walls of the screwless clip 400 b to reduceand/or prevent sliding movement of the screwless clip 400 b and/or anassociated PV module frame. For example, the edge lip 535 interfacingwith the locking recession 442 b may prevent any backing out and/orother removal of the screwless clip 400 b.

FIG. 6A illustrates a view of an example embodiment of a first mountingassembly 600 a including the screwless clip 400 a and the mountingpurlin 500 a coupled to a PV module frame 610 according to the presentdisclosure. The PV module frame 610 may include one or more frameflanges 620 that are flat or substantially flat and may be positionedflush against a top surface of the mounting flanges of the mountingpurlin 500 a. Although the mounting flanges and the frame flanges 620are illustrated in FIG. 6A as having the same shape and surface area,some offset in alignment between the mounting flanges and the frameflanges 620 may be tolerated and are contemplated within the presentdisclosure. Additionally or alternatively, although the mounting flangesand the frame flanges 620 are illustrated in FIG. 6A as having the samethickness, some disparities in flange thickness may be tolerated. Inthese and other embodiments, the screwless clips 400 a may includevarying configurations in which the slot openings 425 of the screwlessclips 400 a include differing lengths, widths, and/or heights toaccommodate mounting flanges 520 and/or frame flanges 620 of varyingthicknesses and/or lengths.

In some embodiments, the screwless clip 400 a may be coupled to themounting assembly 600 a such that the upward-oriented locking tabs 440of the screwless clip 400 a interface with a bottom surface of the frameflange 620 of the PV module frame 610 through the slots in the mountingpurlin 500 a, and the downward-oriented grounding teeth 430 of thescrewless clip 400 a interface with a top surface of the frame flange620 of the PV module frame 610. The locking tabs 440 interfacing withthe bottom surface of the frame flange 620 and/or the grounding teeth430 interfacing with the top surface of the frame flange 620 mayincrease the gripping force that the screwless clip 400 a exerts on theframe flange 620 of the PV module frame 610 and/or the flange of themounting purlin 500 a such that relative sliding movements between thePV module frame 610 and the mounting purlin 500 a are reduced and/orprevented. Additionally or alternatively, the frame flanges 620 mayinclude slots that correspond to the slots of the mounting purlin 500 a.

While the example of a single screwless clip 400 a is illustrated, itwill be appreciated that multiple screwless clips 400 a may be used tocouple the PV module frame 610 with the mounting purlin 500 a.

FIG. 6B illustrates a second assembly view of the example embodiment ofthe first mounting assembly 600 a according to the present disclosure.As shown in FIG. 6B, the locking tabs of the screwless clip 400 a mayextend through the slots of the mounting purlin 500 a and interface withthe bottom surface of the frame flange 620 of the PV module frame 610.

FIG. 6C illustrates a side view of the example embodiment of the firstmounting assembly 600 a according to the present disclosure. Asillustrated in the side view of the mounting assembly 600 a, thegrounding teeth 430 and/or the locking tabs 440 may interface with thetop and/or bottom surfaces of the frame flange 620 of the PV moduleframe (not shown), respectively.

In some embodiments, the PV module frame may include a thin layer ofanodized aluminum, which is typically electrically insulative. In theseand other embodiments, the layer of anodized aluminum may range from onemicron to ten microns in thickness. To facilitate grounding of the PVmodule through the mounting purlin, the grounding teeth 430 may cut intothe layer of anodized aluminum such that the screwless clip 400 a is indirect contact with an electrically conductive material underneath thelayer of anodized aluminum. In these and other embodiments, thescrewless clip 400 a may facilitate grounding of a given PV modulethrough the PV module frame to which the given PV module is attached byproviding a low-resistance grounding path through the mounting purlin.

FIG. 6D illustrates a front view of the example embodiment of the firstmounting assembly 600 a according to the present disclosure. In someembodiments, the shape of the screwless clip 400 may facilitate thesecure attachment of the screwless clip 400 to the mounting purlinand/or the PV module frame. The longer inner walls 420 of the screwlessclip 400 may provide structural strength for the screwless clip 400 in avertical direction, which may prevent the PV module frame and/or themounting purlin from separating under load. Additionally oralternatively, the shorter outer walls 410 of the screwless clip 400 mayprovide opposing spring forces that reduce and/or dissipate rattling,vibrations, sliding, etc. of the screwless clip 400 during operation ofthe PV modules.

FIG. 6E illustrates an isometric view of an example embodiment of asecond mounting assembly 600 b including the screwless clip 400 b andthe mounting purlin 500 b coupled to the PV module frame 610 accordingto the present disclosure. A top edge of the outer wall of the screwlessclip 400 b may interface with a bottom surface of the mounting flange ofthe mounting purlin 500 b, and the grounding teeth of the screwless clip400 b may interface with a top surface of the frame flange 620 of the PVmodule frame 610. The edge flange 535 at the end of the mounting flangeof the mounting purlin 500 b may interface with the locking recession442 b to reduce and/or prevent sliding movement of the screwless clip400 b, the mounting purlin 500 b, and/or the PV module frame 610.

FIGS. 7A-7C illustrate various example embodiments of screwless clips700 a-c according to the present disclosure. In some embodiments, ascrewless clip 700 a, as illustrated in FIG. 7A, may include one or moreouter walls 710 a connected to one or more 720 a inner walls in which anangle of bending between the outer walls 710 a and the inner walls 720 ais wider than an angle of bending between the two inner walls 720 a.Stated another way, the gap between the top of the two inner walls 720 amay be wider than the gap between the bottom of the two inner walls 720a. The angle of bending between two given walls may adjust thecompression force between the mounting flange of the mounting purlin andthe frame flange of the PV module frame. For example, a wider angle ofbending between the inner walls 720 a of the screwless clip 700 a mayreduce the contact between an upward-facing edge of the outer walls 710a and the bottom surface of the mounting flange and/or the bottomsurface of the frame flange (e.g., the contact between the locking tabs440 and the bottom surface of the frame flange through the mountingslot), which may reduce the compression force between the mountingpurlin and the PV module frame. As another example, a narrower angle ofbending between the inner walls 720 a may increase the contact betweenthe upward-facing edge of the outer walls 710 a and the bottom surfacesof the of the mounting flange and/or the frame flange, which mayincrease the compression force between the mounting purlin and the PVmodule frame.

In some embodiments, a screwless clip 700 b, as illustrated in FIG. 7B,may include one or more outer walls 710 b that each include a cutoffsection 715 b. Removing a portion of the outer wall 710 b beyond thecutoff section 715 b may increase the elasticity of the outer wall 710 brelative to longer outer walls (e.g., the outer walls 410, the outerwalls 710 a, and/or outer walls 710 c). In these and other embodiments,the inner walls 720 b of the screwless clip 700 b may include one ormore chamfers 725 b that reduce the sharpness of the edges of the innerwalls 720 b such that installation of the screwless clip 700 b may beeasier and/or less dangerous for installation technicians (e.g.,inserting the screwless clip 700 b by hand).

In some embodiments, outer walls 710 c of a screwless clip 700 c mayeach include a cutout portion 715 c as illustrated in FIG. 7C. Forexample, the screwless clip 700 c may include the cutout portion 715 cat a transition between the outer walls and the inner walls withmaterial connecting the outer walls and the inner walls on both ends ofthe cutout portion 715 c. The cutout portions 715 c may provideclearance for squeezing the inner walls 720 c of the screwless clip 700c together (e.g., by hand, using pliers, etc.), which may facilitateeasier installation of the screwless clip 700 c on the mounting flangeand/or the frame flange.

The subject technology of the present disclosure is illustrated, forexample, according to various aspects described below. Various examplesof aspects of the subject technology are described as numbered examples(1, 2, 3, etc.) for convenience. These are provided as examples and donot limit the subject technology. It is noted that any of the dependentexamples or portions thereof may be combined in any combination, andplaced into an independent example, e.g., Examples 1, 2, and 3. Theother examples can be presented in a similar manner. The following is anon-limiting summary of some examples presented herein.

Example 1 includes a module mounting system that may include aphotovoltaic (PV) module frame enclosing one or more PV cells. Themodule mounting system may include a mounting rail shaped to interfacewith the PV module frame and one or more support structures to which themounting rail is coupled to keep the mounting rail off the ground. Themodule mounting system may include a spring clip with a PV module frameinterfacing portion and a mounting rail interfacing portion in which thespring clip is shaped to apply spring force via deformation of thespring clip to force the mounting rail and the PV module frame againsteach other.

In some examples, the module mounting system may further comprise asecond PV module frame adjacent to the PV module frame. The PV moduleframe and the second PV module frame may include a first flange and asecond flange, respectively, and the first flange and the second flangemay extend in opposite directions and each interface with a top surfaceof the mounting rail. The PV module frame interfacing portion of thespring clip may include at least a first and a second wing in which thefirst wing is configured to slide over the first flange and the secondwing to slide over the second flange such that the first wing interfaceswith a top surface of the first flange and the second wing interfaceswith a top surface of the second flange to fix both the PV module frameand the second PV module frame in place relative to the mounting rail.

In some examples, the PV module frame may include a lock ramp formedinto a bottom surface of the mounting rail, and the mounting railinterfacing portion of the spring clip may include a central loopconfigured to slide over the lock ramp into a final position where thespring clip is forcing the mounting rail and the PV module frame againsteach other. In these and other examples, the lock ramp may include aprofile that facilitates sliding the central loop over the lock ramp ina first direction when moving into the final position and preventssliding the central loop over the lock ramp in a second direction backout of the final position.

In some examples, the mounting rail may include a slot and at least aportion of the spring clip may be configured to be inserted through theslot to couple the spring clip to the mounting rail. In these and otherexamples, the module mounting system may further comprise a second PVmodule frame adjacent to the PV module frame. The PV module frame andthe second PV module frame may include a first flange and a secondflange, respectively, in which the first flange and the second flangeextend in opposite directions. Both the first flange and the secondflange may interface with a top surface of the mounting rail, and boththe first flange and the second flange may each include a respectivehole. The spring clip may include first and second arms configured toproject into the holes of the first and second flanges to facilitaterotation of the spring clip and fixing the first and the second PVmodule frames in place relative to the mounting rail. In these and otherexamples, the slot may be shaped to include a lock ramp having aprotruding shape that facilitates sliding the portion of the spring clipinserted through the slot in a first direction to a final position andprevents sliding the spring clip inserted through the slot in a seconddirection out of the final position.

Example 2 includes a spring clip that may include an upper componentincluding one or more arms. The spring clip may include a lowercomponent including a central loop in which the upper component and thelower component are configured to rotate relative to each other about ahinge point to transition from an initial position to a final positionin which the final position causes the arms of the upper component tointerface with a PV module frame and the central loop of the lowercomponent to interface with a mounting rail to force the mounting railand the PV module frame against each other.

In some examples, the hinge point may be at an interface between theupper component and the lower component, include a post in one of theupper and the lower components, and include a hole through which thepost projects in an other of the upper and the lower components. Inthese and other examples, the arms of the upper component may beconfigured to rotate from below the PV module frame to above the PVmodule frame such that the arms of the upper component press against atop surface of the PV module frame in the final position.

In some examples, the mounting rail of the PV module frame may includeone or more holes, and the ends of the lower component may be configuredto extend through the holes of the mounting rail to form a pivot pointthat facilitates rotation of the spring clip relative to the mountingrail.

In some examples, the arms of the upper component may extend upward andbe sized to extend through corresponding holes in both the mounting railand the PV module frame to interface with a top surface of the PV moduleframe and a majority of the upper component extending below a topsurface of the mounting rail.

Example 3 includes a module mounting system that includes a mountingpurlin including one or more mounting flanges extending horizontallyfrom the mounting purlin and a PV module frame including one or moreframe flanges extending horizontally from the PV module frames in whicheach of the frame flanges may interface against a respective mountingflange of the mounting purlin. The module mounting system may includeone or more screwless clips interfacing with the mounting flanges andthe frame flanges in which each of the screwless clips includes one ormore outer walls and one or more inner walls formed of a continuoussheet of material in a generally W-shaped profile.

In some examples, a gap between a top of the inner walls may be widerthan a gap between a bottom of the inner walls.

In some examples, a height of each of the inner walls may be greaterthan a height of each of the outer walls. In these and other examples,the screwless clip may include a slot in the inner walls extending amajority of a length of the screwless clip in which the screwless clipinterfaces with the mounting flanges and the frame flanges at least inthe slot. In these and other examples, the screwless clip may include aplurality of grounding teeth positioned along the slot with thegrounding teeth configured to interface with a surface of the frameflange and bite through an anodized layer of the frame flange toelectrically couple the frame flange and the mounting flange.

In some examples, one or more of the outer walls may include a pluralityof locking tabs oriented in an upward-facing direction positioned alongrespective edges of the outer walls. The outer walls may each include alocking recession positioned along a same respective edge of the outerwalls as the plurality of locking tabs with the locking recession beingpositioned closer to the centers of the respective edges of the outerwalls than the plurality of locking tabs and having a lower height thanthe plurality of locking tabs. In these and other examples, each of thescrewless clips may include a cutout portion at a transition between theouter walls and the inner walls with material connecting the inner wallsand the outer walls on both ends of the cutout portion. In these andother examples, each of the mounting flanges may include an edge lipsuch that the respective edge lip interfaces with the locking recessionof the respective screwless clip.

The various features illustrated in the drawings may be, but are notnecessarily, drawn to scale. The illustrations presented in the presentdisclosure are not meant to be actual views of any particular apparatus(e.g., device, system, etc.) or method, but are merely idealizedrepresentations that are employed to describe various embodiments of thedisclosure. Accordingly, the dimensions of the various features may bearbitrarily expanded or reduced for clarity. In addition, some of thedrawings may be simplified for clarity. Thus, the drawings may notdepict all of the components of a given apparatus (e.g., device) or alloperations of a particular method.

Terms used in the present disclosure and especially in the appendedclaims (e.g., bodies of the appended claims) are generally intended as“open terms” (e.g., the term “including” should be interpreted as“including, but not limited to.”).

Additionally, if a specific number of an introduced claim recitation isintended, such an intent will be explicitly recited in the claim, and inthe absence of such recitation no such intent is present. For example,as an aid to understanding, the following appended claims may containusage of the introductory phrases “at least one” and “one or more” tointroduce claim recitations. However, the use of such phrases should notbe construed to imply that the introduction of a claim recitation by theindefinite articles “a” or “an” limits any particular claim containingsuch introduced claim recitation to embodiments containing only one suchrecitation, even when the same claim includes the introductory phrases“one or more” or “at least one” and indefinite articles such as “a” or“an” (e.g., “a” and/or “an” should be interpreted to mean “at least one”or “one or more”); the same holds true for the use of definite articlesused to introduce claim recitations.

In addition, even if a specific number of an introduced claim recitationis expressly recited, those skilled in the art will recognize that suchrecitation should be interpreted to mean at least the recited number(e.g., the bare recitation of “two recitations,” without othermodifiers, means at least two recitations, or two or more recitations).Furthermore, in those instances where a convention analogous to “atleast one of A, B, and C, etc.” or “one or more of A, B, and C, etc.” isused, in general such a construction is intended to include A alone, Balone, C alone, A and B together, A and C together, B and C together, orA, B, and C together, etc.

Further, any disjunctive word or phrase preceding two or morealternative terms, whether in the description, claims, or drawings,should be understood to contemplate the possibilities of including oneof the terms, either of the terms, or both of the terms. For example,the phrase “A or B” should be understood to include the possibilities of“A” or “B” or “A and B.”

All examples and conditional language recited in the present disclosureare intended for pedagogical objects to aid the reader in understandingthe present disclosure and the concepts contributed by the inventor tofurthering the art, and are to be construed as being without limitationto such specifically recited examples and conditions. Althoughembodiments of the present disclosure have been described in detail,various changes, substitutions, and alterations could be made heretowithout departing from the spirit and scope of the present disclosure.

What is claimed is:
 1. A module mounting system comprising: a mountingpurlin including one or more mounting flanges extending horizontallyfrom the mounting purlin; a PV module frame including one or more frameflanges extending horizontally from the PV module frames, each of theframe flanges interfacing against a respective mounting flange of themounting purlin; and one or more screwless mounting clips configured tointerface with the mounting flanges and the frame flanges of thephotovoltaic (PV) module frame, each of the screwless mounting clipsincluding one or more outer walls and one or more inner walls formed ofa continuous sheet of material in a generally W-shaped profile.
 2. Themodule mounting system of claim 1, wherein a gap between a top of theinner walls of each of the screwless mounting clips may be wider than agap between a bottom of the inner walls.
 3. The module mounting systemof claim 1, wherein a height of each of the inner walls of each of thescrewless mounting clips is greater than a height of each of the outerwalls.
 4. The module mounting system of claim 3, wherein the screwlessmounting clip includes a slot in the inner walls extending a majority ofa length of the screwless mounting clip, the screwless mounting clipinterfacing with the mounting flanges and the frame flanges at least inthe slot.
 5. The module mounting system of claim 4, wherein thescrewless mounting clip includes a plurality of grounding teethpositioned along the slot, the grounding teeth configured to interfacewith a surface of the frame flange and bite through an anodized layer ofthe frame flange to electrically couple the frame flange and themounting flange.
 6. The module mounting system of claim 1, wherein oneor more of the outer walls include: a plurality of locking tabs orientedin an upward-facing direction positioned along respective edges of theouter walls; and a locking recession positioned along a same respectiveedge of the outer walls as the plurality of locking tabs, the lockingrecession being positioned closer to centers of the respective edges ofthe outer walls than the plurality of locking tabs and having a lowerheight than the plurality of locking tabs.
 7. The module mounting systemof claim 6, wherein each of the screwless mounting clips includes acutout portion at a transition between the outer walls and the innerwalls with material connecting the inner walls and the outer walls onboth ends of the cutout portion.
 8. The module mounting system of claim6, wherein each of the mounting flanges include an edge lip such thatthe respective edge lip interfaces with the locking recession of therespective screwless mounting clip.